By Melissa Donovan
The science behind adhesive technology is multi-faceted, complicated, and constantly evolving. In the pressure-sensitive adhesive (PSA) space, particularly those used in conjunction with wide format print media, there is a continued movement to achieve an environmentally friendly solution while providing the desired performance characteristics of the application at hand, more often than not this includes heightened levels of durability, strong adhesion, and resistance to moisture.
Developed Over Time
Before we talk about today’s adhesive systems found on PSA materials, it’s important to discuss those of the past, which illustrates the success the technology has achieved. “Modern adhesives have come a long way from their origins as byproducts of the livestock industry. Over time, they’ve become more advanced and fine tuned, offering greater control over specific performance characteristics for a range of applications. Today’s adhesives are primarily made from synthetic polymers, which provide the stability as well as the performance needed for modern graphic installations,” shares Jay Kroll, director of product education, General Formulations.
Daniel Farias, technical engineer, Drytac, says rubber was one of the first materials used for PSA. “Over the years rubber PSA technology has advanced to include both natural and synthetic rubber resins and a variety of tackifiers used to tune the adhesive for specific performance.”
Rubber-based PSAs offered good tack, but limited UV and temperature resistance, admits Aarona Tesch, product marketing manager, ACCO Brands – GBC/SEAL.
Acrylics started to be used for PSAs “because of the tendency of natural rubber to yellow and degrade when exposed to UV. Acrylic chemistry also tends to have higher internal strength than rubber chemistry,” explains Farias.
“The move to acrylic PSAs was due to its superior clarity, UV resistance, and durability,” adds Tesch.
Shifting towards more sophisticated acrylic and even synthetic rubber systems has made an impact on the industry as a whole, providing more flexibility for smaller coaters and laminators to enter the market, notes Steve Blackowicz, VP of sales, Jessup Manufacturing Company.
Acrylic systems were mostly solvent-based, but water-based became prevalent as environmental concerns arose. “The adhesive systems of the past were mostly solvent-based in order to have the durability and the aggressiveness to really bite into the substrate. Water-based adhesive was available and for a better price but did not have the desired performance characteristics for many applications. European companies began moving to water-based adhesives because of environmental regulations,” says Nate Goodman, technical product manager, Mactac.
Today’s PSA
When discussing today’s PSA, a variety of options are still paired with vinyl/film optimized for wide format digital printing.
According to Tesch, solvent- and water-based adhesives are the two most popular systems. They can either be made out of rubber or acrylic polymers, with solvent-based adhesive polymers dissolved in organic solvents and water-based adhesive polymer dispersed in water.
Solvent-based adhesives offer strong adhesion, good durability, and resistance to moisture and chemicals, says Tesch. They are ideal for long-term outdoor signage, vehicle wraps, and high-performance graphics. Not ideal are longer drying times, volatile organic compound (VOC) emissions, and environmental concerns.
“Though these new technologies improved over the years and can be used for many of our applications, we consistently find that when requiring the highest performance, durability, and our ability to adapt them, solvent technologies still reign superior,” adds Blackowicz.
Water-based adhesives offer low VOCs, are easy to handle, and environmentally friendly. Used for indoor graphics, they also excel in short- to medium-term outdoor applications, states Tesch. Negatives to consider are lower initial tack and slower drying in humid conditions.
When determining whether rubber- or acrylic-based adhesive is used, “the most common adhesive systems used on printable media for wide format printing are solvent and water-based acrylics,” explains Farias.
Acrylic adhesives are what Farias refers to as the “workhorses” in wide format printing. This is because of their overall heat resistance, long-term adhesion, and non-yellowing characteristics. Acrylic adhesives are used in both short- and long-term applications and the resins are adapted to enhance mechanical performance capabilities such as shear strength.
Kroll explains the process of how the acrylic-based adhesive system comes to be. “The acrylic is combined with water or solvent to allow for coating onto the film and liner, then cured in an oven to remove the liquid and leave behind the adhesive.”
“Water-based acrylic uses water as the carrier, some refer to is as emulsion. It is cost affective. The characteristics continue to improve, approaching acting more like a solvent adhesive. It is less expensive, but has less clarity because of additives,” says Goodman.
On the other hand, solvent-based acrylics use solvent as a carrier. They offer “high durability, are aggressive, and feature good clarity, but are costly and have environmental concerns,” cites Goodman.
UV-Cured Adhesives
As acrylic adhesives gain ground, UV-curable acrylic variants coincidentally make headway. “UV cured adhesives are becoming much more prevalent in PSA coating for wide format printing,” admits Farias.
They are fast curing, offer excellent clarity, and high chemical resistance. “High-end graphics, optically clear films, and specialty applications benefit from UV-curable adhesives,” shares Tesch.
According to Bryan Baab, product development manager – wide format, Nekoosa in an interview posted on Nekoosa’s website in March 2025, UV technology can create adhesion that rivals or even surpasses that of solvent adhesives with the same variety in application surfaces—and especially more challenging application surfaces like low surface energy plastics, textured walls, concrete, and polished stone. Also, most UV adhesives offer a fairly quick and simple installation and removal process with minimal mess or tools.
In addition to those benefits, Blackowicz says UV-cured adhesives also offer high durability and reduced environmental impact. Unfortunately, “there are less to choose from and technology is still evolving. They are less easy to modify at the coater for tailored applications but are a big push in the industry.”
UV-cured adhesives differ from water- or solvent-based options. “UV-cured adhesives are a different system, more similar to epoxy. They combine monomers, oligomers, and a photoinitiator, which are mixed and coated onto the film or liner. Exposure to UV light causes these components to crosslink, forming a solid adhesive. While the end result—a pressure-sensitive adhesive—is similar, the chemistry and curing methods are distinct,” explains Kroll.
Perhaps preventing a more accelerated adoption of UV adhesives is the misconception that they don’t provide the print quality and clarity of their solvent-based counterparts. “This is one of the more common misconceptions about UV adhesives, but the truth is that the UV-curing process actually creates a final product that is cleaner than solvent-based curing and free from blemishes like dirt or ash. Unlike solvent adhesives, UV does not require long ovens for drying during the manufacturing process. This helps enhance the transparency and clarity of the graphic over the course of its service life,” shares Baab in the same interview.
Derivatives of Note
While rubber and acrylic are the two main adhesive categories; and solvent-, water-, and UV-based sub segments, there are two other PSA segments to take note of.
Microsphere/repositionable PSAs, according to Blackowicz, feature unique structures for low-tack, removable, and repositionable applications. These are ideal for graphics that require frequent changes.
Specialty PSAs include silicone or butyl. These are used for niche applications that may require extreme temperature resistance or unique substrate compatibility, adds Blackowicz.
The Future of Adhesive
While acrylic-based adhesives have staying power, UV-cured adhesives continue to be top of mind. In fact any PSA that can offer sustainable as well as “smart” features seems to be where the future of adhesives is headed.
“The future of adhesive technology for PSA vinyl and film in wide format printing is shaped by a combination of sustainability, performance innovation, and user-centric design. Key trends and developments include sustainability and eco-conscious formulations, enhanced performance and durability, smart and functional adhesives, application-specific customization, and continued user-friendly converting and installation,” lists Tesch.
Kroll agrees that adhesive technology is shifting towards more sustainable—as well as smarter—solutions. “Low-VOC, water-based systems are evolving to meet environmental standards while maintaining performance. At the same time, advanced repositionable adhesives are gaining traction, making installation easier and more forgiving—especially for non-professional users. As printing methods improve and graphic applications expand, adhesives will continue to evolve—offering better performance, easier handling, and more environmentally responsible formulations than ever before.”
“The next generation of PSA adhesives is focused on sustainability, performance, and smart functionality,” states Blackowicz. Two examples of this are what he refers to as smart adhesives and production efficiency. Smart adhesives are the “integration of sensing technologies for temperature or pressure responsiveness. Production efficiency translates to faster curing, less waste, and lower energy consumption and lower barrier to entry for coaters and people that want to get into coating.”
The push to eco-friendly formulations is why UV-cured adhesives are seeing a positive response.
“UV-cured coating lines that help manufacture these materials will continue to expand due to the overall performance of the adhesives and to help with overall sustainability. UV-cured adhesives will have the same performance level as solvent-based adhesives and eliminate the exposure of the solvents in the environment,” foresees Farias.
Conversely, Blackowicz believes “many are pushing UV-cured acrylics hard and time will tell if performance can match solvent, but the same was said on water-based acrylics and they have yet to get there after 20 years.”
On the whole, “formulations continue to improve. There will be a wider range of products but also more adhesives that are good for a variety of applications. Look for improved stability with vinyl due to plasticizers. Formulations for PVC-free products and improved sustainability options will also meet future regulatory demands,” adds Goodman.
Adhesive Developments
Whether rubber or acrylic; solvent-, water-, or UV-based, a number of adhesive options are available depending on the needs dictated by the application at hand. A lot of individual factors play into the decision like whether the material is placed outdoors or inside, the temperature, and for how long it is installed. The future of PSA involves sustainability and smart adhesion features.
Oct2025, Digital Output
